Composition door



March 10, 1936. R. 1 DAvlsoN 2,033,884

COMPOS ITION DOOR Filed Dec. 20, 1932 2 Sheets-Sheet 1 Rober l.. D uson H ATTORNEY March 10, 1936. R, l DAWSON COMPOSITION DOOR Filed Deo. 20, 1932 2 Sheets-Sheet 2 Eil@ L@ Xiu .Dri

Patented Mar. l0, 1936 COMPOSITION DOOR Robert L. Davison, New York, N. Y., assignor to John B. Pierce Foundation, New York, corporation of New York N. Y., a

Application December 20, 1932, Serial No. 648,135

1 Claim.

My'present invention relates to building construction and more particularly to an improved type of door.

A feature of my invention is the production of a door as a unitary structure.

A feature of my invention is the production of a relatively sound-proof door composed of a plurality of diiferent kinds of material united into a unitary structure. Y

A feature of my invention is the production of a unitary sound-proof door in which the pivoting members are formed as an integral part of the door structure.

A feature of my invention is a relatively soundproof door comprising a core of high sound and heat insulating qualities, hermetically encased in an enclosing shell.

A feature of my invention is an improved heatinsulating door or similar structure by hermetically encasing a core of material having high insulating qualities as regards heat and sound, the encasing material being molded into shape under the influence of heat and pressure.

In the accompanying drawings illustrating a preferred embodiment of my invention and the method by which the same is made,

Fig. l is a section through a door structure or panel of any desired size;

Fig. 2 is a fragmentary view of one of the corners of a panel, such as is shown in Fig. 1, and with the enclosing material on one face thereof removed;

Fig. 3 is a perspective view showing the lower end of a door or panel and showing the constructional details thereof;

Fig. 4 is a fragmentary view partly in section showing the upper corner of a panel or door and illustrating the method of forming the pivotal hardware integral therewith; Y

Fig. 5 is a fragmentary view in section of the lower corner of a door or panel and showing a pintle mounting means formed integral therewith;

Fig. 6 is a bottom plan view of Fig. 5; and

Fig. 7 is a sectional elevation showing a press and illustrating the method of manufacture of my improved door or panel.

Referring to the drawings, there is shown a core Ill of relatively high insulating properties as regards heat and sound, such core I 0 being of any desired shape and thickness, the outer contour following closely but being smaller than the contour of the door or panel desired to be formed, and having a thickness less than the finished thickness of the door or panel. Such core I0 is encased in a shell of moldable material, any material of this character being suitable and preferably such material is one having high resistance to abrasion, practically immune from warping, and resistant to acids, alkalies and the like.

The casing is composed of what may be termed a border II extending completely about the periphery of the core I0 and formed integral with the molding II, and covering each face of the core I0 are plates I2. It is understood of course that the molding II and plates I2 are formed of the same material and are molded into an integral structure, so that the core I0 is hermetically encased therein. By reference to Fig. 2, the method in which the said molding is folded about a corner of the core Ill is readily apparent.

As stated above, the door or panel may be of any size or shape as regards peripheral outline and thickness, and when utilized as a door, it is sometimes desirable to have the pivot hardware formed integral with the door structure. In such event and referring to Fig. 4, it will be seen that the core I0 at the places where the hinge plate I3 is to be attached is cut away as indicated by the reference numeral I 4, after which the hinge member I3 is placed in position and held in position with respect to the door under construction, and when the moldable material II is subjected to heat and pressure, such moldable material will flowv in and around the portion of the hinge I3 within the limits of the structure under construction, and such material II will iiow through the holes I5 to positively hold the hinge member I3 in position. Y

It may sometimes happen that a door adapted to be swung on pintles is employed, and in this case the upper and lower corners of the door structure have the core I0 thereof cut away and excess material I I is placed in this cut away portion, and in molding a metal or other pin I6 is 4 held in the mold and the mold is so formed as to make the portion of the molding I I thicker than the portion surrounding the hole made by the pin I 6 than in the ordinary form of door. Such construction may be apparent from a study of 45 Figs. 5 and 6.

The panel or door is molded at a single operation and when in completed form, the insulating material I0 is hermetically sealed in a casing of the moldable material. Any material which will 50 ow under the influence of heat and pressure may be employed, and such material may be any resin compound or any compound such as Bakelite and the like, but preferably I use the material known as Vinolyte, which in addition to the and pressure has the further additional property property of flowing under the influence of heat of being non-warping after the moldingoperation has vtaken place.

In carrying out the method of making panels or doors under my present invention, I preferably utilize a press consisting of a platen or base /I1`ln' which the upper face is cut away to appropriate size as regards outline and depth o'f the required finished panel or door, as indicated by the reference numeral I8. I also provide vent holes, as the Vent holes I9I through which gases driven out of the moldable material vand out of the insulating material I Il may iiow and 'thus avoid the danplaten I1, Ilmay make the bottom face of the platen I1 relatively thin and have the same rest in a fiat coil which will `be the equivalent of the plurality of parallelly arranged and interconnected pipes'20. Associated with the platen I1 is a plunger 22 which has a peripheral contour similar to the contour of the opening` I8 in the upper face of the'platen II.

Means are also provided in the platen Il for either rapidly heating or cooling the same as by the forming of a plurality of interconnected pipes 23 therein, all connectedto a pipe 24, which in l turn is connected to means for attaching the same to a source of steam under pressure or to a source of cold water or other cooling liquid.

l es

In the process o'f forming my improved panel or door, I utilize sheets or plates 25 of the material to form the molding I I and face plates I2, and such material is utilized until the entire surface of the bottom of the cut away portion J8 is entirely covered; to provide for the filling of the interstices between such plates 25, I may siftor place powder formed of the material 25 in order to make an even layer of the material over the bottom of the opening I8.

0n top of the plates 25 is carefully arranged' a core I0 of the desired thickness and of a peripheral size less than the peripheral size of the opening I8, this being necessary to provide the end thicknesses or molding I I, referred to in connection with Figs. 1 and 2. 'After the core I0 is in position, the molding II is placed in position as shown in Fig. 7, and the space not taken up by either the molding I I or core Il) is filled with the powdered material 26. Afterwards, the molding II and top face of thecore I0 are covered with plates 25 and the interstices between such plate 25 illled with the powdered material 26.

'I'he plunger 22 is 'then placed in position, as shown in Fig. 7, and the whole placed in a press and the structure subjected to heat and pressure. The volumetric displacement of the core I II before the pressing operation is of course greater than the desired finished 4volumetric displacement,v and such displacement can be readily calculated to any degree desired.

The pressure and heating are continued until the moldable material within the cavity I 8 of the platen I1 ows, and such vowing of the material will cause the plates 25 and molding II to flow 4into a homogeneous mass. j

During the operation vof subjecting the structure to pressure, any moisture within the core I0 will be forced out and will be driven through the t perforations I9 vin the platen I 1. The str-ucture to. be manufactured is, after the moldablev 1 material has begun to flow, held under heatv and.

pressure for a period of approximately five min-l utes, although moreor less time may be consumedif desired.

While the pressure is maintained after this period, the heat is removedfrom' the heating devices and cold water' substituted therefor,` which has the effect of rapidly chilling both the:4A platen Il and the plunger 22 rapidity of construction.

VIn addition, the sudden chilling of the platen `and plunger imparts a relatively high finish to and thus facilitates and plunger in engagement with the moldable v material are in themselves^highly polished.

Also, the sudden chilling .of the platen and plunger enables the resulting panel or door to acquire a permanentset and it has been found that after such permanent set'has taken place,

that the panel or door-*will not be subject to warping.

While I havenecessarily described the preferred embodiment of. my invention and the method by which the same is produced somewhat in detail, it is to be understood that I may vary `the size, shape and arrangement of parts comprising the devices and the various steps inthe process of producing the same within relatively wide limits Without departing from the spirit of i 'the invention.

able device of this character, and obviously, I may utilize a mold having a peripheral band to define the limits'of the area of the desired panel and have associated therewith ,a pair of plungers operated simultaneously and by any desired means, sc as to move toward each other under pressure.

Or, the device shown in 7 may be such thatv the plunger and the'platen are independently mounted and movable relatively toward each other. v

I claim:

An integral door unit comprising a mass of insulating material, molded material wholly enveloping said mass of insulating material, the peripheral edges vof said molded material serving as the peripheral edges of the door being substantially thicker than the thickness of said mass of insulating material, said molded material being provided'with an additional quantity along one edge, and a hinge member embedded in said `additional quantity whereby said insulating material, said enveloping molding material and said hinge member form an integral door unit, said hinge member projecting beyond'said edge of said molded material. ROBERT L. DAVISON. 

